Teflon fuser member containing fluorinated nano diamonds

ABSTRACT

Exemplary embodiments provide a coating composition for an outermost layer of a fuser member that can include a plurality of fluorinated diamond-containing particles dispersed in a fluororesin matrix.

DETAILED DESCRIPTION

1. Field of Use

The present teachings relate generally to fuser members used forelectrostatographic devices and, more particularly, to a fuser memberhaving an outermost layer that includes fluorinated diamond-containingparticles dispersed in a fluororesin matrix.

2. Background

In electrostatography, also known as xerography, electrophotographicimaging or electrostatographic imaging, an imaging process includesforming a visible toner image on a support surface (e.g., a sheet ofpaper). The visible toner image is often transferred from aphotoreceptor that contains an electrostatic latent image and is usuallyfixed or fused onto the support surface using a fuser member to form apermanent image.

In current electrophotographic processes, two major types of fuseroutermost materials are used for the fusing technologies. The two majortypes of materials include fluoroelastomers, for example, VITON® fromE.I. DuPont de Nemours, Inc. (Wilmington, Del.), and fluoroplastics, forexample, TEFLON® also from E.I. DuPont de Nemours, Inc. (Wilmington,Del.).

VITON® fluoroelastomers are used to provide the fuser members goodmechanical flexibility with an ability to absorb shock energy. Also,VITON® fluoroelastomers allow high speed operation with high printquality VITON® fluoroelastomers have more of a “rubber” property and maybe used in conjunction with release agents or fusing oils.

TEFLON® fluoroplastics are widely used for oil-less fusing, i.e., withno fusing oils required during fusing operations. TEFLON® fluoroplasticsmay include a TEFLON® PFA (perfluoroalkylvinylether copolymer) surfacedisposed over a conformable silicone layer, which enables rough paperfix and good uniformity. In addition, the TEFLON® PFA surface mayprovide thermal/chemical resistance for the fuser members. Problemsstill arise, however, due to insufficient mechanical strength anddecreased wear resistance of the TEFLON® materials.

Conventional approaches for solving these problems include addingfillers into the outermost materials of fuser members. Conventionalfillers include carbon black, metal oxides, and carbon nanotubes (CNTs).However, other fillers to further improve mechanical properties (e.g.,modulus and/or hardness) and wear resistances of the outermost fusermaterials are still desirable.

Thus, there is a need to overcome these and other problems of the priorart and to provide a coating composition for an outermost fuser materialhaving fluorinated diamond-containing particles.

SUMMARY

According to various embodiments, the present teachings include acoating composition that includes a mixture of a fluororesin polymer anda plurality of fluorinated diamond-containing particles. The fluorinateddiamond-containing particle can include a chemically active shell layerover a diamond core, while the chemically active shell layer can includean atom of fluorine. The coating composition can be used as an outermostfuser material for electrostatographic/electrophotographic printingdevices with improved mechanical-/electrical-/surface-properties, andthe life time.

According to various embodiments, the present teachings also include afuser member. The fuser member can include an outermost layer disposedover a substrate. The outermost layer can further include a plurality offluorinated nano diamond-containing particles dispersed in afluoroplastic matrix. The fluorinated nano diamond-containing particlecan include a chemically active shell layer, which is fluorinated, overa chemically inert diamond core. In embodiments, one or more otherfunctional layers can be disposed between the substrate and theoutermost layer for the disclosed fuser member.

According to various embodiments, the present teachings further includea method for making a fuser member. To make the fuser member, a coatingcomposition can be formed to include a fluororesin polymer and aplurality of fluorinated diamond-containing particles in an aqueoussolution. In this solution, the fluorinated diamond-containing particlecan include a chemically active shell layer disposed over a diamond corewith the chemically active shell layer including an atom of fluorine.Such coating composition can then be applied to a belt substrate to forman outermost layer of the fuser member. In embodiments, one or morefunctional layers can be formed between the belt substrate and theoutermost layer to form the disclosed fuser member.

Additional objects and advantages of the present teachings will be setforth in part in the description which follows, and in part will beobvious from the description, or may be learned by practice of thepresent teachings. The objects and advantages of the present teachingswill be realized and attained by means of the elements and combinationsparticularly pointed out in the appended claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the present teachings, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several embodiments of thepresent teachings and together with the description, serve to explainthe principles of the present teachings.

FIG. 1A is a schematic showing an exemplary structure of a diamond coreused for fluorinated diamond-containing particles in accordance withvarious embodiments of the present teachings.

FIG. 1B depicts a portion of an exemplary fuser belt member inaccordance with various embodiments of the present teachings.

FIG. 1C is a schematic showing an exemplary outermost layer used for thefuser member in FIG. 1B in accordance with various embodiments of thepresent teachings.

FIG. 2 is a schematic illustrating an exemplary fuser subsystem of aprinting apparatus in accordance with various embodiments of the presentteachings.

It should be noted that some details of the FIGS. have been simplifiedand are drawn to facilitate understanding of the embodiments rather thanto maintain strict structural accuracy, detail, and scale.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to embodiments of the presentteachings, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts.

In the following description, reference is made to the accompanyingdrawings that form a part thereof, and in which is shown by way ofillustration specific exemplary embodiments in which the presentteachings may be practiced. These embodiments are described insufficient detail to enable those skilled in the art to practice thepresent teachings and it is to be understood that other embodiments maybe utilized and that changes may be made without departing from thescope of the present teachings. The following description is, therefore,merely exemplary.

Exemplary embodiments provide materials and methods for a coatingcomposition for an outermost fuser material and the related fusermember. The coating composition and the outermost fuser material caninclude fluorinated diamond-containing particles dispersed in a polymermatrix that includes one or more fluororesins, fluoroplastics, or otherresins. A fuser member that includes the disclosed outermost fusermaterial can be used in electrophotographic printing devices andprocesses. Exemplary fuser members can have improved mechanicalproperties, surface wear resistance, and life time.

As used herein and unless otherwise specified, the term “fluorinateddiamond-containing particles” refers to any “diamond-containingparticles” that contain atoms of fluorine. For example, the “fluorinateddiamond-containing particles” can include fluoro-functional groups thatare physically bonded (e.g., ionic bond, hydrogen bond, or van derwalls) or chemically bonded (i.e., covalent bond) to thediamond-containing particles.

As used herein and unless otherwise specified, the term“diamond-containing particles” can include a core-shell structure havinga chemically active shell layer surrounding a chemically inert diamondcore. For example, the chemically active shell layer can include carbonblack of sp² carbon that shells around a diamond core of sp³ carbon. Thesp² carbon black shell can be chemically modified with variousfunctional groups (including fluoro-groups), while the sp³ diamond corecan not be chemically modified due to the saturated carbon of diamondcore.

In various embodiments, the “diamond-containing particles” can becommercially available in a form of powder or dispersion, for example,from Nanoblox, Inc. (Boca Raton, Fla.). Examples of commerciallyavailable diamond-containing particles can include raw nano diamondblack (e.g., product NB50) possessing 50 percent of sp³ carbon core and50 percent of sp² carbon shell, and nano diamond grey (e.g., productNB90) possessing 90 percent of sp³ carbon core and 10 percent of sp²carbon shell.

In various embodiments, the “fluorinated diamond-containing particles”can also be commercially available, for example, from Nanoblox, Inc.(Boca Raton, Fla.). Examples of commercially available fluorinateddiamond-containing particles can include product NB90-F possessing 90percent of sp³ carbon core and 10 percent of sp² carbon shell that isfluorinated.

In various embodiments, the fluorinated diamond-containing particles canbe formed by fluorinating the chemically active shell, e.g., the carbonblack sp², of the diamond-containing particles. For example, thecore-shelled diamond-containing particles can be treated by reactingwith fluorine, while the amount of fluorine can be varied in order toproduce specific desired properties. In various embodiments, thefluorinated diamond-containing particles can be concentrated with, forexample, poly(carbon monofluoride), poly(dicarbon monofluoride) or theircombinations. Specifically, poly(carbon monofluoride) can have a formulaof CF_(x), wherein x represents the number of fluorine atoms and is anumber of from about 0.01 to about 1.5, while poly(dicarbonmonofluoride) is usually written in the shorthand manner of (C₂F)_(n) asknown to one of ordinary skill in the art.

The methods for fluorination are well known and documented in theliterature, such as in the U.S. Pat. No. 6,397,034, entitled“Fluorinated Carbon Filled Polyimide Intermediate Transfer Components,”which is herein incorporated by reference in its entirety. Generally,the fluorination can be conducted by heating the carbon black shell ofthe diamond-containing particles with elemental fluorine at elevatedtemperatures, such as from about 150° C. to about 600° C. A diluent suchas nitrogen can be preferably admixed with the fluorine. The nature andproperties of the resulting fluorinated particles can vary with theconditions of reaction and with the degree of fluorination obtained inthe final product. The degree of fluorination in the final product maybe varied by changing the process reaction conditions, principally,temperature and time. For example, the higher the temperature and thelonger the time, the higher the fluorine content.

In various embodiments, the fluorinated diamond-containing particles caninclude a fluorine content ranging from about 1 percent to about 40percent by weight of the total particles. In an additional example, thefluorine content can range from about 2 percent to about 30 percent byweight of the total fluorinated diamond-containing particles, or in somecases, rang from about 5 percent to about 20 percent by weight of thetotal particles.

In various embodiments, the fluorinated diamond-containing particles canbe surface modified to provide additional functional surfaces. Forexample, the chemically active shell layer of the particles can bemodified to have a spectrum of chemically functional groups selectedfrom the group consisting of —OH, —COOH, —NH₂, —SO₃H, alkyl,carboxylated amine and quaternerized amine.

These functional groups can be directly linked to, e.g., the sp² carbonblack shell, and can further provide desired properties for thefluorinated diamond-containing particles. For example, when surfacedmodified by —OH, —COOH, —NH₂, alkyl, —SO₃H, or their combinations, themodified “fluorinated diamond-containing particles” can have a betterdispersion in a polymer/organic system (e.g., a fluoroelastomer organicsystem) compared with unmodified “fluorinated diamond-containingparticles”. In another example, when surface modified by quarternizedamine, carboxylated amine or their combinations, the modified“fluorinated diamond-containing particles” can have a better dispersionin an aqueous polymer system (e.g., an aqueous fluororesin system)compared with unmodified “fluorinated diamond-containing particles”.

In various embodiments, the fluorinated diamond-containing particles caninclude nano-diamond particles having a size in the nanometer range fromabout 1 nm to about 1000 nm (1 micron). In various embodiments, thefluorinated nano diamond-containing particles can have a size rangingfrom about 1 nm to about 100 nm, or from about 20 nm to about 50 nm. Itshould be noted that size ranges can vary depending on a particular useor configuration of a particular application.

As used herein, average particle size refers to the average size of anycharacteristic dimension of a diamond-containing particle based on theshape of the particle(s), e.g., the median grain size by weight (d₅₀) asknown to one of ordinary skill in the art. For example, the averageparticle size can be given in terms of the diameter of substantiallyspherical particles or nominal diameter for irregular shaped particles.Further, the shape of the particles can not be limited in any manner.Such nano-particles can take a variety of cross-sectional shapesincluding round, oblong, square, euhedral, etc.

In various embodiments, the fluorinated diamond-containing particles canbe in a form of, for example, nanospheres, nanotubes, nanofibers,nanoshafts, nanopillars, nanowires, nanorods, nanoneedles and theirvarious functionalized and derivatized fibril forms, which includenanofibers with exemplary forms of thread, yarn, fabrics, etc. Invarious other embodiments, the fluorinated diamond-containing particlescan be in a form of, for example, spheres, whiskers, rods, filaments,caged structures, buckyballs (such as buckminster fullerenes), andmixtures thereof.

In various embodiments, the fluorinated diamond-containing particles canhave a diamond core having a hardness of from about 9 to about 10 onMohs hardness scale, where 10 is the maximum value on the Mohs hardnessscale, e.g., for pure diamond particles. In some embodiments, thediamond core can have a hardness of from about 9.5 to about 10, or insome cases, form about 9.7 to about 10.

In various embodiments, the diamond core of the fluorinateddiamond-containing particles can be formed from natural or syntheticdiamond or combinations thereof. Natural diamonds typically have aface-centered cubic crystal structure in which the carbon atoms aretetrahedrally bonded, which is known as sp³ bonding. Specifically, eachcarbon atom can be surrounded by and bonded to four other carbon atoms,each located on the tip of a regular tetrahedron. Further, the bondlength between any two carbon atoms is 1.54 angstroms at ambienttemperature conditions, and the angle between any two bonds is 109degrees. The density of natural diamond is about 3.52 g/cm³. Arepresentation of carbon atoms bonded in a normal or regular tetrahedronconfiguration in order to form diamond is shown in FIG. 1A. In oneembodiment, nano-diamonds can be produced by detonation of diamondblend, for example, followed by a chemical purification.

Synthetic diamond is industrially-produced diamond which is formed bychemical or physical processes, such as chemical vapor deposition orhigh pressures. Like naturally occurring diamond, the synthetic diamondcan include a three-dimensional carbon crystal. Note that syntheticdiamond is not the same as diamond-like carbon, which is an amorphousform of carbon.

Examples of synthetic diamond which can be useful for the exemplaryembodiments can include polycrystalline diamond and metal bond diamond.Polycrystalline diamond can be grown by chemical vapor deposition as aflat wafer of, e.g., up to about 5 mm in thickness and up to about 30 cmin diameter or in some cases, as a three-dimensional shape.Polycrystalline diamond can have a popcorn-like structure. The diamondis usually black but can be made completely transparent. The crystalstructure can be octahedral. Metal bond forms of synthetic diamond canbe formed by pressing a mixture of graphite and metal powder forextended periods at high pressure. For example, a nickel/iron basedmetal bond diamond is produced by placing a graphite and nickel ironblended powder into a high pressure high temperature (HPHT) press for asufficient period of time to form a product which imitates naturaldiamond. Other metals, such as cobalt, can also be used. After thediamond is removed from the press, it is subjected to a milling process.A chemical and thermal cleaning process can be utilized to scrub thesurfaces. It may then be micronized to provide a desired size range. Theparticles thus formed can be flakes or tiny shards, with no consistentshape The crystal structure can be monocrystalline, as for naturaldiamond.

In various embodiments, the fluorinated diamond-containing particles canbe used to form composite materials used as outermost layer of fusermembers.

For illustrative purposes, although the term “fuser member” is usedherein throughout the application, it is intended that the term “fusermember” also encompasses other members useful for a printing process orin a printer including, but not limited to, a fixing member, a pressuremember, a heat member, and/or a donor member. In various embodiments,the “fuser member” can be in a form of, for example, a roller, acylinder, a belt, a plate, a film, a sheet, a drum, a drelt (crossbetween a belt and a drum), or other known form for a fuser member.

In certain embodiments, the fuser member can include a substrate that isin a form of a belt substrate or a roll substrate. The thickness of thesubstrate in a belt configuration can be from about 50 μm to about 300μm, and in some cases, from about 50 μm to about 100 μm. The thicknessof the substrate in a cylinder or a roll configuration can be from about2 mm to about 20 mm, and in some cases, from about 3 mm to about 10 mm.

FIG. 1B depicts a portion of an exemplary fuser belt member 100 inaccordance with the present teachings. It should be readily apparent toone of ordinary skill in the art that the member 100 depicted in FIG. 1Brepresents a generalized schematic illustration and that othercomponents/layers/films/particles can be added or existingcomponents/layers/films/particles can be removed or modified.

As shown, the fuser member 100 can include a belt substrate 110, and anoutermost layer 120 disposed over the belt substrate 110.

In various embodiments, one or more other functional layers can bedisposed between the belt substrate 110 and the outermost layer 120. Forexample, the outermost layer 120 can be formed over a resilient layer(e.g., a silicone layer) that is formed over the belt substrate 110. Inanother example, an interfacial layer may further be disposed betweenthe resilient layer and the outermost layer 120.

As disclosed herein, the belt substrate 110 can include, but is notlimited to, a belt, a plate, a film, a sheet, or a drelt. In variousembodiments, the belt substrate 110 can include a wide variety ofmaterials, such as, for example, metals, metal alloys, rubbers, glass,ceramics, plastics, or fabrics. In an additional example, the metalsused can include aluminum, anodized aluminum, steel, nickel, copper, andmixtures thereof, while the plastics used can include polyimide,polyester, polyetheretherketone (PEEK), poly(arylene ether), polyamideand mixtures thereof.

In various embodiments, the outermost layer 120 can include a pluralityof fluorinated diamond-containing particles dispersed in a polymermatrix to provide an improved mechanical robustness, surface wearresistance, surface hydrophobicity, and/or thermo- orelectrical-conductivity of the fuser member 100.

As used herein, the “polymer matrix” used for the disclosed outermostlayer 120 can include one or more resins, such as, for example,fluororesins, fluoroplastics, and/or other thermosetting orthermoplastic resins. Examples of suitable fluororesins orfluoroplastics can include polytetrafluoroethylene, copolymer oftetrfluoroethylene and hexafluoropropylene, copolymer oftetrafluoroethylene and perfluoro(propyl vinyl ether), copolymer oftetrafluoroethylene and perfluoro(ethyl vinyl ether), copolymer oftetrafluoroethylene and perfluoro(methyl vinyl ether), or combinationsthereof.

In various embodiments, fluororesins or fluoroplastics can becommercially known under various designations as TEFLON® PFA(polyfluoroalkoxypolytetrafluoroethylene), TEFLON® PTFE(polytetrafluoroethylene), and TEFLON® FEP (fluorinatedethylenepropylene copolymer). The TEFLON® designations are Trademarks ofE.I. DuPont de Nemours, Inc. (Wilmington, Del.). In a specificembodiment, the polymer matrix used for the outermost layer 120 can beTEFLON® PFA.

FIG. 1C is a schematic showing an exemplary outermost layer 120 a usedfor the fuser member 100 of FIG. 1B in accordance with the presentteachings. It should be readily apparent to one of ordinary skill in theart that the outermost layer depicted in FIG. 1C represent a generalizedschematic illustration and that other particles/fillers/layers can beadded or existing particles/fillers/layers can be removed or modified.

As shown, the outmost layer 120 a can include a plurality of fluorinateddiamond-containing particles 125 dispersed within a polymer matrix 128.In various embodiments, the plurality of fluorinated diamond-containingparticles 125 can be used as a filler material and can be dispersedrandomly, uniformly and/or spatially-controlled throughout the polymermatrix 128, so as to substantially control, e.g., enhance, the physicalproperties including mechanical robustness, and/or,thermal-/electrical-conductivities of the resulting polymer matricesused as fuser materials in a variety of fusing subsystems andembodiments. In addition, the incorporation of disclosed fluorinateddiamond-containing particles 125 can improve wear resistance of theoutermost layer 120 due to a low friction coefficient. Further, theincorporation of disclosed fluorinated diamond-containing particles 125can reduce surface free energy and/or increase surface hydrophobicity ofthe outermost layer 120, and thus provide an oil-less fusing surface.

In various embodiments, the outermost layer 120 can have an improvedmechanical property such as an improved hardness as compared withconventional outermost layers (e.g., TEFLON® only) without using thedisclosed particles 125. Hardness can generally be measured by, forexample, Rockwell hardness test, Brinell hardness test, Vickers hardnesstest, Knoop hardness test, and Pencil hardness test as known to one ofordinary skill in the art. In various embodiments, the outermost layer120 can have a hardness of about 1H or higher measured by the Pencilhardness test. In some cases, the hardness of the outermost layer 120can range from about 1H to about 4H, or range from about 2H to about 4H.

In various embodiments, the outermost layer 120 can have an improvedelectrical conductivity, i.e., a reduced electrical resistivity. Forexample, the outermost layer 120 can have a surface resistivity of about10¹⁵ ohm/sq or less. In an additional example, the surface resistivityof the outermost layer 120 can range from about 10⁵ ohm/sq to about 10¹⁵ohm/sq, or range from about 10⁷ ohm/sq to about 10¹² ohm/sq.

In various embodiments, the outermost layer 120 can have a desiredoutermost surface suitable for an oil-less fusing. Specifically, theoutermost surface can be more hydrophobic as compared with conventionalmaterials (e.g., TEFLON® only) without incorporating the disclosedparticles 125. For example, the outermost surface can have a watercontact angle of about 110 degrees or greater, or in some cases, rangingfrom about 110 degree to about 150 degree. In specific embodiments, theoutermost surface can be super hydrophobic having a water contact angleof about 150 degree or greater.

In various embodiments, the disclosed outermost layer 120 a can have athickness of from about 1 micron to about 200 microns, in some cases,from about 10 microns to about 150 microns, or from about 20 microns toabout 100 microns. In various embodiments, the polymer matrix 128 canaccount for at least about 50 percent and, in some embodiments, at leastabout 60 percent or at least about 70 percent by weight of the outermostlayer 120 a. The plurality of fluorinated diamond-containing particles125 can be at least about 1 percent by weight of the outermost layer 120a and, in some embodiments, at least about 5 percent or at least about10 percent by weight of the outermost layer 120 a.

In various embodiments, the outermost layer 120 can further includeother fillers, such as inorganic particles within the polymer matrix128. In various embodiments, the inorganic particles can be selectedfrom the group consisting of metal oxides, non-metal oxides, and metals.Specifically, the metal oxides can be selected from the group consistingof silicon oxide, aluminum oxide, chromium oxide, zirconium oxide, zincoxide, tin oxide, iron oxide, magnesium oxide, manganese oxide, nickeloxide, copper oxide, antimony pentoxide, and indium tin oxide. Thenon-metal oxides can be selected from the group consisting of boronnitride, and silicon carbides (SiC). The metals can be selected from thegroup consisting of nickel, copper, silver, gold, zinc, and iron. Invarious embodiments, other additives known to one of ordinary skill inthe art can also be included in the diamond-containing coatingcomposites.

In various embodiments, a coating composition can be formed to preparethe disclosed outermost layer 120, 120 a. The coating composition can beprepared to include, for example, an effective solvent, in order todisperse the plurality of fluorinated diamond-containing particles, oneor more polymers and/or corresponding curing agents; and optionally,inorganic filler particles or surfactants that are known to one of theordinary skill in the art.

The effective solvents can include water or organic solvents including,but not limited to, methyl isobutyl ketone (MIBK), acetone, methyl ethylketone (MEK), and mixtures thereof. Other solvents that can formsuitable dispersions can be within the scope of the embodiments herein.

Various embodiments can thus include methods for forming the fusermember 100 using techniques including, but not limited to, coatingtechniques, extrusion techniques and/or molding techniques. As usedherein, the term “coating technique” refers to a technique or a processfor applying, forming, or depositing a dispersion to a material or asurface. Therefore, the term “coating” or “coating technique” is notparticularly limited in the present teachings, and dip coating,painting, brush coating, roller coating, pad application, spray coating,spin coating, casting, or flow coating can be employed. For example, gapcoating can be used to coat a flat substrate, such as a belt or plate,whereas flow coating can be used to coat a cylindrical substrate, suchas a drum or fuser roll. Coated members can then be formed havingvarious configurations.

In a certain embodiment, the coating composition can include an aqueousdispersion including fluorinated diamond-containing particles, TEFLON®fluoroplastics, and, optionally, inorganic fillers (e.g., MgO). Forbetter dispersion in aqueous solution, fluorinated diamond-containingparticles can be further modified with, for example, a quaternerizedamine such as —NH—(CH₂)_(n)—N⁺R₁R₂R₃, where n is from about 1 to about8; and R₁, R₂ and R₃ each independently represents hydrogen, alkylhaving from about 1 to about 16 carbon atoms, or a carboxylated aminesuch as —N⁺R₄R₅R₆(CH₂)_(m)COO⁻, where m is from about 1 to about 8; andR₄, R₅ and R₆ each independently represents hydrogen, and alkyl havingfrom about 1 to about 16 carbon atoms. The coating composition can thenbe deposited, coated, or extruded on a substrate, such as a beltsubstrate, followed by a curing process. In various embodiments, thecoating composition can be partially or wholly evaporated for a timelength prior to the curing process to form the outermost layer. Thecuring process can be determined by the polymer(s) used and can include,for example, a step-wise curing process. However, any curing schedulesknown to those skilled in the art can be within the scope of embodimentsherein.

In an exemplary embodiment, the coated member can be used as a fusermember having a belt configuration. FIG. 2 schematically illustrates anexemplary fuser subsystem 200 in a belt configuration of a xerographicprinter in accordance with the present teachings. The exemplary fusersubsystem 200 can include a fuser belt 100 a and a rotatable pressureroll 212 that can be mounted forming a fusing nip 211. A media 220carrying an unfused toner image can be fed through the fusing nip 211for fusing.

In various embodiments, the fuser belt 100 a and the pressure roll 212can include a top-coat layer or an outermost layer 120, 120 a, aplurality of fluorinated diamond-containing particles 125 dispersed inan exemplary fluoroplastic 128, disposed over a belt substrate 110 asshown in FIGS. 1B-1C. The outermost layer 120, 120 a can thus have acontinual self-releasing surface, an improved mechanical property,surface wear resistance and desired thermal-/electrical-conductivity.

Specifically, the disclosed exemplary outermost layer 120, 120 a of thefuser member 110, 100 a including a plurality of fluorinateddiamond-containing particles 125 dispersed in a fluororesin 128possesses a low surface energy and chemical inertness, needed foroil-less fusing. In addition, the fluorinated diamond-containingparticles 125 in the outermost layer 120 can result in an increase inthe top-coat modulus, and a decrease in lead or side edge wear sincepaper edges may slide upon contact with a low surface energy fusingsurface desired for long life of the fuser member 110, 110 a.

EXAMPLES Example 1 Preparation of an Outermost Fuser Material

A coating composition is prepared by mixing the fluorinated nano diamondparticles (NB90-F, 90 percent of sp³ carbon and 10 percent offluorinated sp² carbon available from Nanoblox Inc., Boca Raton, Fla.)with TEFLON® PFA TE7224 from DuPont in water with a weight ratio of10/90.

The prepared coating composition is then coated on an exemplary glassplate to form a film via a draw bar coating process.

The film is further heated to cure at high temperatures of from about300° C. to about 400° C., or about 360° C. for a period of from about 1to about 60 minutes, or about 10 minutes to form a chemically andthermally stable, tough coating with increased electrical conductivityand improved mechanical properties. Such coating is used as an outermostfuser material.

While the present teachings have been illustrated with respect to one ormore implementations, alterations and/or modifications can be made tothe illustrated examples without departing from the spirit and scope ofthe appended claims. In addition, while a particular feature of thepresent teachings may have been disclosed with respect to only one ofseveral implementations, such feature may be combined with one or moreother features of the other implementations as may be desired andadvantageous for any given or particular function. Furthermore, to theextent that the terms “including”, “includes”, “having”, “has”, “with”,or variants thereof are used in either the detailed description and theclaims, such terms are intended to be inclusive in a manner similar tothe term “comprising.” As used herein, the term “one or more of” withrespect to a listing of items such as, for example, A and B, means Aalone, B alone, or A and B. The term “at least one of” is used to meanone or more of the listed items can be selected.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the present teachings are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements. Moreover, all ranges disclosedherein are to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” can include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 5. In certain cases, the numerical values asstated for the parameter can take on negative values. In this case, theexample value of range stated as “less than 10” can assume values asdefined earlier plus negative values, e.g. −1, −1.2, −1.89, −2, −2.5,−3, −10, −20, −30, etc.

Other embodiments of the present teachings will be apparent to thoseskilled in the art from consideration of the specification and practiceof the present teachings disclosed herein. It is intended that thespecification and examples be considered as exemplary only, with a truescope and spirit of the present teachings being indicated by thefollowing claims.

1. A fuser member comprising: a substrate; and an outermost layerdisposed over the substrate, wherein the outermost layer comprises aplurality of fluorinated nano diamond-containing particles dispersed ina fluoroplastic matrix and wherein each particle of the plurality offluorinated nano diamond-containing particles comprises a chemicallyactive shell layer that is fluorinated over a chemically inert diamondcore.
 2. The member of claim 1, wherein the substrate is a belt, aplate, a film, a sheet, or a drelt.
 3. The member of claim 1, whereinthe substrate is formed of a material selected from the group consistingof a metal, a plastic, and a ceramic, wherein the metal comprises amaterial selected from the group consisting of an aluminum, an anodizedaluminum, a steel, a nickel, a copper, and mixtures thereof, and whereinthe plastic comprises a material selected from the group consisting of apolyimide, a polyester, a polyetheretherketone (PEEK), a poly(aryleneether), a polyamide, and mixtures thereof.
 4. The member of claim 1,wherein the chemically active shell layer comprises a sp² carbon blackand a functional group comprising a quarternized amine, a carboxylatedamine or combinations thereof.
 5. The member of claim 1, wherein theplurality of fluorinated diamond-containing particles are present in theoutermost layer in an amount of from about 1 percent to about 50 percentby weight.
 6. The member of claim 1, wherein the fluoroplastic matrixcomprises a material selected from the group consisting ofpolytetrafluoroethylene, copolymer of tetrifluoroethylene andhexafluoropropylene, copolymer of tetrafluoroethylene andperfluoro(propyl vinyl ether), copolymer of tetrafluoroethylene andperfluoro(ethyl vinyl ether), copolymer of tetrafluoroethylene andperfluoro(methyl vinyl ether) and combinations thereof.
 7. The member ofclaim 1, wherein the surface of the outermost layer has a water contactangle of from about 110 degrees to about 150 degrees.
 8. The member ofclaim 1, wherein the outermost layer has a surface resistivity rangingfrom about 10⁵ ohm/sq to about 10¹⁵ ohm/sq.
 9. The member of claim 1,wherein the outermost layer has a hardness of from about 1H to about 4Hmeasured by a pencil hardness test.
 10. The member of claim 1, whereinthe chemically active shell layer comprises a sp² carbon black and afunctional group comprising —OH, —COOH, —NH₂, —SO₃H, alkyl, acarboxylated amine, a quaternized amine or combinations thereof.